External Cooling Block for Battery Pack Leakage Prevention
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Solution Overview
Problem
Conventional battery packs are prone to dielectric breakdown and potential fires when cooling water leaks from the cooling block, as it directly contacts the battery modules and can flow into the case, causing insulation breakdown and damage to internal components.
Innovation Solution
The cooling block is positioned outside the case, with concave portions forming cooling paths and a heat transfer substance between the battery modules and the bottom plate, allowing cooling water to flow externally and preventing it from entering the case, while maintaining effective heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the cooling block is disposed inside the case in direct contact with battery modules, then cooling performance is improved, but dielectric breakdown risk increases when cooling water leaks
Solution Approach 1:
The cooling block is extracted from the interior of the case and relocated to the exterior, attached to the bottom surface of the case. This separation removes the source of potential leakage (cooling block) from the sensitive internal environment, eliminating the dielectric breakdown risk while preserving cooling functionality through external water supply passages.
2Reliability
If the cooling block is disposed outside the case, then dielectric breakdown risk is reduced, but cooling efficiency may deteriorate due to increased thermal path
Solution Approach 1:
The bottom plate of the case serves as an intermediary thermal conduction path between the battery modules and the external cooling block. By utilizing the case's bottom plate as a heat transfer medium, the design maintains efficient thermal coupling without requiring the cooling block to be positioned inside the case, thus preserving cooling efficiency while preventing leakage-related damage.
3Temperature
If cooling water supply passages are provided inside the case, then cooling performance is improved, but manufacturing complexity and leakage risk increase
Solution Approach 1:
The cooling water supply passages are extracted from the case interior and relocated to the exterior of the case. The cooling block is equipped with water supply passages on its external surface, allowing cooling water to be supplied from outside the case. This simplifies the overall structure by eliminating the need for complex internal piping and sealing mechanisms within the case.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design prevents dielectric breakdown and potential fires by ensuring cooling water leaks externally, reducing manufacturing costs and maintaining cooling performance, thus safeguarding the battery pack and associated components.
Implementation Method 1
a cooling block (13) attached to a bottom portion of the bottom plate (111) and being provided with cooling water for removing heat generated by the battery modules (17)
Implementation Method 2
a heat transfer substance disposed between the battery modules and the bottom plate
Data Source
Figure 1
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Figure 4
AI summary
A battery pack may include a case including a bottom plate having a surface to which battery modules are mounted; and a cooling block attached to a bottom portion of the bottom plate and being provided with cooling water for removing heat generated by the battery modules.